Eurotrac W11E Operation Manual Download Page 56 | Manualshive

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October 2019

W11E | Operation manual

6.

INSTALLATION AND WIRING

INTERACTIVE DOCUMENTATION

For specific application, refer to the About Controllers Area of the Interactive Documentation.

AC-M2 Wiring Diagram

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Summary of Contents for W11E

Page 1: ...P de Heus en Zonen Greup B V Stougjesdijk 153 3271 KB Mijnsheerenland The Netherlands Tel 31 0 18 66 12 333 E mail info eurotrac nl W11E WHEEL LOADER OPERATION MANUAL ...

Page 2: ...ns 29 3 3 Service 30 3 3 1 Preparation for use 30 3 3 2 Regular maintenance form 31 3 3 3 Oil Lubricant 33 3 4 Troubleshooting 35 3 4 1 Kinetic energy reduction 35 3 4 2 Drive axle 36 3 4 3 Brake system 37 3 4 4 Lithium battery 38 FIGURE 1 W11E HYDRAULIC SCHEMATIC 39 FIGURE 2 ELECTRICAL SCHEMATIC 40 FIGURE 3 BODY LOGO LAYOUT 41 DAILY EQUIPMENT INSPECTION 42 4 SME ELECTRONIC CONTROL SYSTEM 43 4 1 A...

Page 3: ...er Terminals 59 6 3 Main contactor 60 6 4 Fuse 61 6 5 Signal 62 6 5 1 Digital Inputs 63 6 5 2 Analog Inputs 64 6 5 3 Driver Outputs PWM 65 6 5 4 Digital Outputs ON OFF 66 6 5 5 Speed Sensor Inputs 67 6 5 6 Thermal Probe 68 6 5 7 Serial 68 6 5 8 CAN Network 69 6 6 SME external devices description 70 6 6 1 Encoder 70 6 6 2 Displays 71 7 GRAPHICAL INTERFACE 72 ...

Page 4: ...ht not include these latest changes Upon request we can send you the latest version of the manual We reserve the right to make improvements and changes to the loader of a model on our own products without any representation If you need more maintenance information outside of this manual please contact your EUROTRAC dealer Issue date Update number Disassembly Load Replacement instructions ...

Page 5: ... read and be familiar with the instruction manual so that it can be operated in accordance with the rules when starting and using the loader This instruction manual should be kept intact during the life of the loader even if the machine is resold replaced by the user or manager etc This manual is not a training manual but it can also be used as one of the training materials if it is really necessa...

Page 6: ...afe operation knowledge EUROTRAC has always regarded product safety as its responsibility so we pay great attention to the safety of the loader when designing the loader for you Your job is to operate safely The safety of you and others depends on your competent operations especially on your understanding of the following brief safety rules and voluntary compliance Security Information This manual...

Page 7: ...ipment damage 1 Always follow global safety rules in your field 2 Always check for proper operation and lighting brakes steering parking brakes parking brakes and tires before using this loader 3 Do not operate the loader with defective features refer to the operation and service manual of the maintenance section 4 Always wear suitable shoes when handling the device and avoid loose clothing that m...

Page 8: ...r and pump motor that is running or just stopped otherwise it will cause severe burns 18 After the hood back cover is opened make sure to not use clean water or other liquids since they can splash into the controller and the battery causing a short circuit 19 Do not use the battery of this car to start other vehicles NOTE When the vehicle is tilted or rolled over do not jump but hold on tight to t...

Page 9: ...se it will cause severe burns 11 Do not smoke near a lithium battery Always keep the lithium battery away from sparks flames and smoking 12 Always remove the metal bracelet watch strap etc before installing removing or maintaining the lithium battery 13 Do not allow short circuit lithium battery terminals 14 When connecting a lithium battery always connect the positive terminal first to prevent sp...

Page 10: ...fic parameters ignition switch two headlights amber flash direction lights taillights speakers various meters and other circuits Quick disassembly device The attachment of the attachment is controlled by a multi way valve for quick assembly and disassembly Seat The seat of the loader is equipped with a seat belt and can be adjusted back and forth The seat rating is EM8 optional Battery charger The...

Page 11: ...right and when the steering wheel rotates to the left the loader turns to the left Instrument panel Design control panel combined with the best driving comfort and efficiency Switch Ignition switch Waterproof ignition switch for loader including anti restart function Horn control switch Mounted on the underside of the instrument panel Headlight switch Mounted on the underside of the instrument pan...

Page 12: ...eter odometer Steering angle showing the position of the rear wheel Maintenance time prompt Prompt the user to the maintenance time Slow operation This light is on indicating that the vehicle is operating in the slow mode and the speed and lifting speed are reduced Accelerator pedal position 0 to 9 grids Motor temperature overheat alarm Battery power is indicated by 9 stripes 9 Fully charged 0 Emp...

Page 13: ...icator lights By pressing the E S H button you can set the operating mode for your system E Economy S Middle Mode H High Mode H up mode At this time the acceleration deceleration rate and maximum grade of the vehicle are higher It is suitable for transporting a large amount of cargo and climbing a steep slope in a short time but it costs electricity unless it is urgently needed it usually does not...

Page 14: ...be repaired before use Set parking brake Walk around and inspect the loader for damage or missing equipment Check for Pressure and the good state of the pneumatic tires Look for cuts cracks in side walls foreign objects in treads Look for loose wheel nuts Damage to lights Fire extinguishers fully loaded and in place if have Check to see if hydraulic or lubricating oil is leaking If leaks are detec...

Page 15: ... the acceleration pedal slowly with your feet The wheel loader will move to the selected direction To slow the wheel loader slowly release the accelerator pedal and press the left brake pedal For an emergency stop release the accelerator pedal and press brake pedal By releasing the accelerator pedal slowly or quickly the wheel loader can be controlled by flat or sharp braking Press the left pedal ...

Page 16: ...same time pull up hand brake Downhill for the temporary parking Drivers are not allowed to leave the driver s seat and switch to a reverse gear shift right foot should press the micro pedal gently and park slowly at the same time pull up hand brake WARNING Parking on the ramp is not allowed If necessary the car should be parked on a slope due to breakdowns you must pull hand brakes and pad the wed...

Page 17: ...eaching the parking spot shift it into neutral position raise the parking brake and turn off the ignition switch NOTE Safe and efficient loading depends entirely on the operator If you are an experienced driver the following rules will refresh your memory If you are a student they will help you to become a professional driver WARNING Only qualified and licensed drivers allowed to drive WARNING Bef...

Page 18: ...id operation leads to accidents Always lower the lifting frame during interruptions and at the end of the shift Lifting frame movements are controlled by the joystick The joystick is located to the right of the driver s seat Lifting frame Move the joystick backwards the lifting frame rises Move the joystick forwards the lifting frame lowers Move the joystick 2 step forwards the lifting frame is no...

Page 19: ...ydraulics button The left connection is the pressure side the right is the return Push the joystick to the right and simultaneously press the auxiliary hydraulics button The right connection is the pressure side the left is the return This may vary from model to model Please always check this before using the wheel loader with optional equipment Auxiliary hydraulics This can be operated using an a...

Page 20: ... of release rest pressure is swing the first valve handle small handle of multi valve left and right side several times WARNING Even if the engine flameout can also lower the lifting devices and tools WARNING If the tool is not delivered together with the loader it can be only used after the authoritarian of stability and load capacity by the dealer of EUROTRAC General preventive measures Do not o...

Page 21: ...ossroad in the passages and the corridors slow down and horn and drive on the right side of the road Be careful to the pedestrians which can appear suddenly in the way If your trip involves crossing road bridge ensure they are secure and are strong enough to withstand the combined weight of the loader and load When approaching the destination reduce the speed to ensure a smoothly slow stop in the ...

Page 22: ...er must be lifted for service it must be securely blocked so that all 4 four wheels may safely turn MOTOR Hot motors will cause severe burns and cause serious injuries if persons are struck by moving parts or caught in belts DURING SERVICE Turn off the main power If maintenance operation requires starting motor personnel should avoid contact with rotating equipment Disconnect the lithium battery p...

Page 23: ...em disconnecting the battery similarly it also can to prevent unexpected start up when the engine is working Do not check battery status near open fires especially when lithium batteries are recharged Do not smoke in the lithium battery charging area No unauthorized disassembly by non professional personnel Do not tamper with the battery Do not use wires to directly short circuit the outlet of the...

Page 24: ... Straight line kg 1250 Vehicle articulated kg 900 Vehicle parameters Walking speed km h 0 14 Hydraulic Oil L 30 Hydraulic system Hydraulic working elements Working pressure BAR 170 Dimensions mm A Protection device width 950 B Off ground clearance 178 C Tire Center Width 803 D Total width 1104 E Maximum operating height 3480 F Maximum height of bucket fulcrum 2900 G Bucket horizontal height 2649 H...

Page 25: ...ct device top height 2268 S Angle of max lifting height 48 T Max tilting angle 45 U Turning corner of level position surface 48 V Departure angle 23 W Turning corner 45 X Maximum turning radius 2530 Y Out edge radius 2220 Z Inner turn radius 1110 TECHNICAL PERFORMANCE PARAMETER W11E S 860kg T 800kg U 600kg V 480kg ...

Page 26: ...Page 26 72 October 2019 W11E Operation manual ...

Page 27: ...scue only the short haul of the loader is allowed but the following steps should be followed before dragging the loader WARNING Draught loaders are no longer capable of braking and steering Trailer steps Place the shim wedge at the slip side behind the wheel Discharge cargo and equipments Start the tractor The tractor which has sufficient traction and braking force is connected to the towing pin w...

Page 28: ... Tire The loader must be raised or the axles are padded to prevent the tires from coming into contact with the ground The tire pressure must be reduced to 15PSI The loader must be raised and the axle is padded to prevent the tire from contacting the ground The tire pressure must be reduced to 15PSI and sprayed with rubber preservatives Lubricating oil Make sure all the points are lubricated with s...

Page 29: ...injury do not perform cleaning and drying steps with more than 30 PSI air pressure Use eye protection and defense and approve air hose nozzles WARNING Before removing the hydraulic hose the filler cap must be loosened and the residual pressure in the tank must be released CAUTION Do not immerse electronic components packaging or rubber plastic or plastic parts in a cleaning solvent Wipe the parts ...

Page 30: ... hydraulic tank loosen the filler cap and slowly release the pressure before opening Grease points Add in each grease point 1 All joint bearings 2 All hinges 3 All bushings Lithium battery Connect the lithium battery cable If it is disconnected connect the positive pole first Make sure the lithium battery is fully charged Brake system Check if the brake fluid leaks Slowly start the vehicle release...

Page 31: ...gnal operation x Cab sign lights heaters wiper operation and cab lights if installed x Horn x Hydraulic oil level x 372N M Wheel nut fastening x Drive axle fixing bolts tighten when needed x Tighten the cylinder head bolts and all nuts and bolts Adjust the specific torque to the specific requirements if necessary x Drive axle oil level x Replace the axle oil replace the oil after 50 hours for the ...

Page 32: ...ery slowly raise the shovel foot until the battery leaves the base and pour the fork backwards The lithium battery can be completely removed 6 Barbaric operations are strictly prohibited during operation 7 The replaced lithium battery should not be discarded at will and it should be recycled by the lithium battery manufacturer 8 The above operation is reversed when installing a lithium battery and...

Page 33: ...ller cap 13 Fill the oil filter port with the hydraulic oil until it is full 14 Tighten the oil filter cover back 15 Start the engine run for a while in the idle state repeatedly turn the steering wheel to the left and right to the maximum corner several times let the car slowly drive for dozens of meters and lift down several times and check the oil level again CAUTION Discarded oil should be dis...

Page 34: ...cing hydraulic components in order to avoid component deterioration it is essential to filter and inspect hydraulic fluid before use 2 Do not mix two oils Drive axle Type NLGI grade No 3 lithium grease Rod end joint bearing Type Lithium base grease every 500 hours ...

Page 35: ...Page 35 72 October 2019 W11E Operation manual 3 4 Troubleshooting 3 4 1 Kinetic energy reduction ...

Page 36: ...Page 36 72 October 2019 W11E Operation manual 3 4 2 Drive axle ...

Page 37: ...Page 37 72 October 2019 W11E Operation manual 3 4 3 Brake system ...

Page 38: ...Page 38 72 October 2019 W11E Operation manual 3 4 4 Lithium battery ...

Page 39: ...Page 39 72 October 2019 W11E Operation manual FIGURE 1 W11E HYDRAULIC SCHEMATIC ...

Page 40: ...Page 40 72 October 2019 W11E Operation manual FIGURE 2 ELECTRICAL SCHEMATIC ...

Page 41: ...mark sticker 5 Tire pressure label 23 Lifting capacity sticker 6 Anti slip mat 24 Anti tip sticker 7 Vehicle nameplate 25 Vehicle nameplate cab 8 Lifting label 26 Hydraulic oil label 9 Anti sticker label 27 Seat belt label 10 Danger of crushing hand sticker 28 Anti label 11 Fuel label 12 Water tank anti scald label 13 Anti cutting label 14 Greasing point indication 15 Noise statement label 16 Anti...

Page 42: ...he liquid level is within the operating range and then close the lid Check the inflation pressure of each pneumatic tire Wheel requirements 3 0BAR Adjust tire pressure as required Check for tread damage or wear Remove the stone from the tread and report any damage side tread damage or unusual wear Make sure the headlights are working properly Check other lights including rear tail stop lights and ...

Page 43: ...potential hazard which could result in serious or fatal injury if the precautions or instructions given in the warning notice are not observed Cautions A caution informs the reader of a hazard or a potential hazard which could result in a serious damage to the appliance Information Notices An information notice contains additional not essential pieces of information to complete or to clarify the m...

Page 44: ...tage above under voltage limit and then cycle key switch 3 User Over Voltage Blocking TAU System Battery resistance too high while regenerating Battery disconnected while regenerating Too low voltage level defined by the user Key switch voltage is above the maximum level defined by the user Bring key switch voltage below user over voltage limit and then cycle key switch 4 User Under Voltage Blocki...

Page 45: ... Inverter 1 Current Sensor Fault Blocking All Leakage current due to motor 1 stator short circuit Controller s sensor faulty Current sensor of inverter 1 has an invalid offset reading at key on Cycle key switch 15 Inverter 2 Current Sensor Fault Blocking All Leakage current due to motor 2 stator short Controller s sensor faulty Current sensors of inverter 2 have an invalid offset reading at key on...

Page 46: ...itch 31 Encoder 2 Fault Blocking All Motor 2 encoder failure Motor 2 encoder faulty wirings Motor 2 speed change very fast Electromagnetic noise on the Motor 2 sensor bearing The difference of speed evaluated between two consecutive readings of the encoder is above the fixed limit Cycle key switch 32 Driver Output 1 Open Short Blocking All Open or short circuit of driver output 1 load Driver outpu...

Page 47: ...y switch 44 Interlock Disabled Stopping TAU System Interlock input is not active Interlock input is not active and line contactor is open Activate interlock input 45 Static Return To Off Traction Warning TAU System Traction throttle or direction selector are active at key on after the Emergency Reverse or a controlled stop procedure One or more traction inputs are active at key on after an EMR or ...

Page 48: ...one PDO hasn t been received for the timeout established by the user through the CAN configuration settings for standard application and for electric steering application Cycle key switch 64 Mains Contactor Close Command Timeout Blocking TAU Generic Slave 5 sec after pre charge is ended up the power line is not ready for master Pre charge timer has expired before the master sends the power ready r...

Page 49: ...verify system faults remappingconfiguration Cycle key switch 76 Blocked For System Fault Blocking TAU System Node blocked for system fault Node is blocked because another node has a stopping blocking fault condition Reset system fault stopping condition or verify system faults remappingconfiguration Cycle key switch 77 BMS Wall Charge Blocking TAU System The BMS is recharging the battery The TAU N...

Page 50: ...om default and cycle key switch 103 Internal Hardware Fault 1 Blocking All Internal hardware error s Internal error Cycle key switch 104 Internal Hardware Fault 2 Blocking All Internal hardware error s Internal error Cycle key switch 105 Internal Hardware Fault 3 Blocking All Internal hardware error s Internal error Cycle key switch 106 Internal Hardware Fault 4 Blocking All Internal hardware erro...

Page 51: ...iable DCB technology and exceptionally stable ITC Control Algorithm AC M2 Controller ensures the best performance without use of mechanical differential AC M2 Controller is suitable to control 1 AC Traction motor 1 AC Pump motor 2 AC Traction motor The product is suitable for the following range of applications Counterbalanced Lift Trucks Reach Trucks Order Picking Trucks Very narrow aisle Trucks ...

Page 52: ...ption Type Code SME code for the specific product Rating Data It contains the indication of the input voltages and the output currents supplied by the product Batch Number Production batch number the same value as in barcode below Lot Production Month and Year Motor Type AC Asynchronous 3 Phase Braking Regenerative Modulation PWM Pulse Width Modulation Switching Frequency 9kHz Low RDS on MOSFET 16...

Page 53: ...ITAL IN 3 Digital Input 4mA pull up VL 1V VH 3 5V TO BE ASSIGNED 5 DIGITAL IN 4 Digital Input 4mA pull up VL 1V VH 3 5V TO BE ASSIGNED 6 DIGITAL IN 5 Digital Input 4mA pull up VL 1V VH 3 5V TO BE ASSIGNED 7 DIGITAL IN 6 Digital Input 4mA pull up VL 1V VH 3 5V TO BE ASSIGNED 8 DIGITAL OUT 1 Digital Output Low side 0 5A TO BE ASSIGNED 9 COIL RETURN Supply Output High side 5A max Positive common 10 R...

Page 54: ...OUND Negative logic supply 10 MOTOR THERMAL PROBE 1 Analog Input Pull up Motor 1 temperature probe 11 MOTOR THERMAL PROBE 2 Analog Input Pull up Motor 2 temperature probe 12 ANALOG IN 1 Analog Input 0 12V pull down TO BE ASSIGNED 13 ANALOG IN 2 Analog Input 0 12V pull down TO BE ASSIGNED 14 DIGITAL IN 12 Digital Input 4mA pull up VL 1V VH 3 5V TO BE ASSIGNED 15 DIGITAL IN 13 Digital Input 4mA pull...

Page 55: ...ll responsibility of the regulatory compliance of the vehicle system with the controller installed 5 4 Operating Environment Specifications Storage ambient temperature range 40 C 70 C Operating ambient temperature range 40 C 55 C Heatsink operating temperature range 40 C 95 C With linear derating 80 C 95 C Protection Level IP65 Vibration Tested under conditions suggested by EN60068 2 6 5g 10 500Hz...

Page 56: ...56 72 October 2019 W11E Operation manual 6 INSTALLATION AND WIRING INTERACTIVE DOCUMENTATION For specific application refer to the About Controllers Area of the Interactive Documentation AC M2 Wiring Diagram ...

Page 57: ...ltage hazard and high current arcs batteries can supply high voltage and very high power and arcs can occur if they are short circuited Always disconnect the battery circuit before working on the motor control circuit Wear safety glasses and use properly insulated tools to prevent shorts Never energize the system if the terminals B and B are not tightly connected Lead acid batteries charging or di...

Page 58: ...n a cover should be used to shield the controller Cables must be routed to prevent liquids flowing into the connections The mounting location should also allow access to all connections The replacement of the Controller must be done with the hand brake engaged the drive wheels off the ground the key switch in off position battery plug disconnected and the capacitors of the inverter completely disc...

Page 59: ...eatsink could be necessary to meet the desired continuous ratings The heat sink material and system should be sized on the performance requirement of the machine We recommend ambient temperature air to be directed over the heatsink fins to maintain heatsink temperature below 75 C 5 In systems where either ventilation is poor or heat exchange is difficult forced air ventilation should be used Clear...

Page 60: ... DC Bus the Controller can close the Main contactor connecting it to the Battery In this way dangerous shocks on Controller s capacitors are avoided Safety In case of dangerous situations the Main contactor must be opened disconnecting the Battery from Controller If the main contactor coil is not connected to the controller the system will not meet EEC safety requirements Sizing In order to select...

Page 61: ...s them so they don t usually cause the fuse to blow Sizing In order to select the Fuse Rating refer to the following formula with c Minimum Controller Efficiency 0 95 and Medium Power Factor You must choose a fuse with specific rating and time delay characteristics It must carry IFUSE indefinitely but blow within maximum 3 seconds for 2 x IFUSE The following diagram shows common dimensions for fus...

Page 62: ...o the AMPSEAL Connectors Product Specification 108 1329 In order to ensure a fine wiring please refer to the AMPSEAL Automotive Plug Connector and Header Assembly Application Specification 114 16016 Number of Positions 23 Mounting Style Wire Termination Style Crimp Contact Type Plug Current Rating 17 A Housing Material Thermoplastic Material Plastic Number of Rows 3 Packaging Bulk Type Female Wire...

Page 63: ... Meaning Pin Meaning K1 2 Digital Input 1 K2 6 Digital Input 9 K1 3 Digital Input 2 K2 7 Digital Input 10 K1 4 Digital Input 3 K2 8 Digital Input 11 K1 5 Digital Input 4 K2 14 Digital Input 12 K1 6 Digital Input 5 K2 15 Digital Input 13 K1 7 Digital Input 6 K2 16 Digital Input 14 K1 12 Digital Input 7 K2 17 Digital Input 15 K1 13 Digital Input 8 K2 18 Digital Input 16 K1 18 I O Ground K2 23 Digita...

Page 64: ...ommend resistance range of external potentiometer is 5 10kΩ Potentiometer connected to Analog Input Analog Inputs on Controller Pin Meaning Pin Meaning K1 18 I O Ground K2 1 5V Out K1 21 12V Out K2 12 Analog Input 1 K2 13 Analog Input 2 K2 19 Analog Input 3 K2 20 Analog Input 4 K2 21 Analog Input 5 K2 22 Analog Input 6 ...

Page 65: ...er pin connected Driver Outputs on Controller Pin Meaning Pin Meaning K1 9 Coil Return K2 1 5V OUT K1 16 Driver Output 1 Max 2A K1 17 Driver Output 2 Max 1 5A K1 20 Driver Output 3 Max 1 5A K1 21 12V Out Driver Outputs Wiring on Controller Positive Reference How to wire Driver Output 1 Driver Output 2 Driver Output 3 Controller 5 12V Battery Voltage External Supply from a DC DC converter Not allow...

Page 66: ...ad The positive reference is given by the other pin connected Digital Outputs on Controller Pin Meaning Pin Meaning K1 8 Digital Output 1 Max 0 5A K2 1 5V OUT K1 9 Coil Return K1 19 Digital Output 2 Max 1 5A K1 21 12V OUT Digital Outputs Wiring on Controller Positive Reference How to wire Controller 5 12V Battery Voltage External Supply from a DC DC converter ...

Page 67: ... Channels are 20mA Pull up with VL 1V and VH 3 5V Encoders Wiring Speed Sensor Inputs on Controller Pin Meaning Pin Meaning K1 21 12V OUT K2 1 5V OUT K2 2 Quad Encoder Channel B2 K2 3 Quad Encoder Channel A2 K2 4 Quad Encoder Channel B1 K2 5 Quad Encoder Channel A1 K2 9 Negative Logic Supply ...

Page 68: ... Inputs on Controller Pin Meaning Pin Meaning K1 18 Negative Logic Supply K2 10 Motor Temperature Probe 1 K2 11 Motor Temperature Probe 2 Thermal Probe supported on Controller Code Meaning DKF103N3 NTC Negative Temperature Coefficient KTY84 130 150 PTC Positive Temperature Coefficient KTY83 121 122 PTC Positive Temperature Coefficient PT 1000 PTC Positive Temperature Coefficient SWITCH NO Normally...

Page 69: ... Sub D connector Interconnection You can communicate with the controller through RS 232 serial port using an interconnection cable USB port using a serial to USB converter Supported Prolific chip Recommended FTDI chip 6 5 8 CAN Network Wiring CAN Network Wiring CAN Network Pins on Controller Pin Meaning K1 15 CAN H K1 23 CAN L K1 22 CAN Ground ...

Page 70: ...cing these resistors on a node should be avoided since the bus line loses termination if the node is disconnected from the bus 6 6 SME external devices description The Controller can be connected to SME external devices described below 6 6 1 Encoder The encoder can detect the rotating motion of the toothed wheel fixed to the motor shaft and it generates two electrical signals square wave and open ...

Page 71: ... 2019 W11E Operation manual 6 6 2 Displays SME displays Compact or Mini are optional devices which show overall information about your system They have to be connected to controller through LIN interface Display Compact ...

Page 72: ...lues each parameter can be calibrated inside an allowable range Operator is easily guided through the process of parameter set up and can communicate with the controller during working operations and can analyze real time main system variables Do not drive the vehicle until initial set up has been completed INTERACTIVE DOCUMENTATION For deep and exhaustive information about programmable parameters...

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